Heat sink structure and manufacturing method thereof

ABSTRACT

A heat sink structure and a manufacturing method thereof. The heat sink includes a main body having multiple main body connection sections and multiple radiating fins each having a connection section. The main body has a first end and a second end. The first and second ends define a longitudinal direction. The multiple radiating fins are placed in a mold. A mechanical processing measure is used to high-speed impact the main body so as to thrust the main body into the mold. Accordingly, the connection sections of the radiating fins placed in the mold are high-speed thrust into the main body connection sections and moved in the longitudinal direction to the second end of the main body to tightly integrally connect with the main body.

This application claims the priority benefit of Taiwan patentapplication number 101127729 filed on Aug. 1, 2012.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a heat sink structure and amanufacturing method thereof, and more particularly to an annular heatsink structure and a manufacturing method thereof.

2. Description of the Related Art

The conventional cylindrical heat sink includes a cylindrical body andmultiple radiating fins connected to the circumference of thecylindrical body. There are several conventional measures for connectingthe radiating fins to the circumference of the cylindrical body. Forexample, a prior art discloses a cylindrical heat sink and a method oftightly planting radiating fins of the heat sink and an applicationdevice thereof. According to the method, a mold seat drivable by a powersource to create stepped rotational operation is provided. A cylindricalbody is located on the mold seat. The circumference of the cylindricalbody is formed with multiple channels. A radiating fin assembly isprovided. The radiating fin assembly includes multiple radiating finsarranged on a lateral side of the mold seat. The cylindrical bodyintermittently rotates to drive and align the channels with theradiating fins. A radiating fin insertion device is used to push theradiating fins and sequentially insert and locate the radiating finsinto the channels of the cylindrical body. After the radiating fins arefully inserted in the channels of the cylindrical body, a successivetightening process is performed to tightly integrally connect theradiating fins to the channels. Accordingly, the radiating fins arelocated on the circumference of the cylindrical body to form a heatsink.

Another prior art discloses a tightening method for a heat sink. Theheat sink includes a heat conduction base seat and a radiating finassembly. One surface of the base seat is formed with multiple channelsand guide grooves positioned between two channels. The radiating finassembly includes multiple radiating fins. A mold having an internalspace and a press end section is provided. A tightening/connectionprocess is performed to press and insert the heat sink into the internalspace of the mold. The press end section is axially thrust into theguide grooves to compress and deform the channels. At this time, theradiating fins are pressed to tightly integrally connect with thedeformed channels. The above method is better than the pressing andriveting method of the conventional heat sink. The breakage of thepuncher or blade mold can be effectively reduced to promote the ratio ofgood products. Also, the precision and quality of the products areincreased. This method is conveniently applicable to various heat sinksto form different types or shapes of heat sinks.

In both the above methods, the radiating fin is first inserted into achannel and then a mold is used to press the guide grooves on two sidesof the channel to deform the channel and press the radiating fin totightly integrally connect the radiating fin with the deformed channel.Such process has some problems as follows:

-   1. The outer surface of the cylindrical body not only is formed with    the channels, but also is formed with the guide grooves. The    channels and the guide grooves are alternately arranged. That is,    the number of the channels per unit surface area is reduced. As a    result, the number of the mounted radiating fins is reduced.-   2. The manufacturing method includes numerous steps so that the    manufacturing time is quite long.

SUMMARY OF THE INVENTION

It is therefore a primary object of the present invention to provide aheat sink structure and a manufacturing method thereof. The main bodyand the radiating fins of the heat sink structure are connected by meansof high-speed impact.

It is a further object of the present invention to provide the aboveheat sink structure, in which the main body connection section of thefirst connection section is formed with a raised/recessed non-planarsurface to enhance connection friction.

It is still a further object of the present invention to provide theabove heat sink structure and the manufacturing method thereof, in whichthe number of the radiating fins per unit surface area is increased.

It is still a further object of the present invention to provide theabove heat sink structure and the manufacturing method thereof, in whichthe heat sink structure has better heat dissipation efficiency.

It is still a further object of the present invention to provide theabove heat sink structure, in which at least one radiating fin isconnected to each main body connection section.

It is still a further object of the present invention to provide theabove heat sink structure, in which the main body connection sectionsare channels radially distributed over the circumference of the mainbody. The main body connection sections are normal to the surface of themain body or inclined to the surface of the main body.

It is still a further object of the present invention to provide theabove heat sink structure, in which the radiating fin is straightwithout bending or is formed with at least one bending angle.

To achieve the above and other objects, the heat sink structure of thepresent invention includes: a main body having a first end and a secondend, the first and second ends defining a longitudinal direction,multiple main body connection sections being formed between the firstand second ends and distributed over a circumference of the main body;and multiple first radiating fins connected with the circumference ofthe main body, each first radiating fin having a first connectionsection corresponding to the main body connection section, a mechanicalprocessing measure being used to high-speed impact the main body towardthe first radiating fins, whereby the first connection sections of thefirst radiating fins are high-speed thrust from the first end of themain body into the main body connection sections and moved in thelongitudinal direction to the second end to tightly integrally connectwith the main body.

In the above heat sink structure, the main body connection section is aconnection channel or a rib, while the first connection section is afirst end edge of the first radiating fin or a connection channel inadaptation to the main body connection section. The main body connectionsection is connected with the first connection section by means of pressfit. The first connection section corresponds to outer surface of themain body and has a guide section. The guide section is a round angle ora reverse angle or a right angle. The main body is formed with multiplethrust sections in communication with the main body connection sections.

In the above heat sink structure, one of the main body connectionsection and the first connection section is formed with araised/recessed non-planar surface, while the other of the main bodyconnection section and the first connection section is formed with aplanar surface or a raised/recessed non-planar surface.

In the above heat sink structure, each main body connection section hasan opening and a bottom end. A straight extension line is defined fromthe opening to the bottom end. The main body connection sections areradially distributed over the circumference of the main body with thestraight extension line passing through the center of the main body.

In the above heat sink structure, each main body connection section hasan opening and a bottom end. A straight extension line is defined fromthe opening to the bottom end. The main body connection sections areinclined to the surface of the main body with the straight extensionline not passing through the center of the main body.

In the above heat sink structure, the first connection section of thefirst radiating fin is formed with a first bending root section.

In the above heat sink structure, the first radiating fin is straightwithout bending or is formed with at least one first bending angle.

The above heat sink structure further includes multiple second radiatingfins. Each second radiating fin has a second connection sectionimmediately adjacent to the first connection section of the firstradiating fin. Along with the first connection section, the secondconnection section is high-speed thrust into the main body connectionsection from the first end of the main body to the second end in thelongitudinal direction, whereby one first connection section and onesecond connection section are tightly integrally fitted in each mainbody connection section with the first radiating fin adjacent to thesecond radiating fin.

In the above heat sink structure, the second connection section is asecond end edge of the second radiating fin.

In the above heat sink structure, the second radiating fin is straightwithout bending or is formed with at least one second bending angle. Theangle of the first bending angle is equal to or unequal to the angle ofthe second bending angle.

In the above heat sink structure, the first radiating fin is made of afirst material, while the second radiating fin is made of a secondmaterial. The first material is a metal material and the second materialis also a metal material. The first material is identical or notidentical to the second material. The metal is selected from a groupconsisting of gold, silver, copper, aluminum and an alloy thereof.

In the above heat sink structure, the first radiating fin has a firstthickness and the second radiating fin has a second thickness. The firstthickness is equal to or unequal to the second thickness.

In the above heat sink structure, the first connection section of thefirst radiating fin is formed with a first bending root section and thesecond connection section of the second radiating fin is formed with asecond bending root section.

The manufacturing method of the heat sink of the present inventionincludes steps of: providing a mold, the mold having an innercircumference, an upper surface and multiple splits, the innercircumference defining an internal space, the multiple splits beingradially formed around the internal space in communication with theinternal space and downward extending from the upper surface; providinga main body having a first end and a second end, the first and secondends of the main body defining a longitudinal direction, multiple mainbody connection sections being formed between the first and second endsand distributed over a circumference of the main body, the first end ofthe main body being aimed at the internal space; providing multipleradiating fins, the radiating fins being received in the splits, atleast one radiating fin being placed in each split, each radiating finhaving a connection section, the connection sections of the radiatingfins protruding from the inner circumference of the mold; and using amechanical processing measure to high-speed impact the main body so asto thrust the main body into the internal space and move the main bodyrelative to the multiple radiating fins, whereby the connection sectionsof the radiating fins are high-speed thrust into the main bodyconnection sections and moved in the longitudinal direction to thesecond end to tightly integrally connect with the main body.

In the above manufacturing method of the heat sink, the main body istemporarily positioned above the mold and the mechanical processingmeasure is an air compression apparatus for creating compressed air tothrust the main body into the internal space. A central body is disposedin the internal space in alignment with the main body.

BRIEF DESCRIPTION OF THE DRAWINGS

The structure and the technical means adopted by the present inventionto achieve the above and other objects can be best understood byreferring to the following detailed description of the preferredembodiments and the accompanying drawings, wherein:

FIG. 1 is a perspective exploded view of the present invention;

FIG. 2 is a perspective assembled view of the present invention;

FIG. 3A is a plane view of the radiating fin of the present invention;

FIG. 3B is a plane view of the radiating fin of the present invention inanother aspect;

FIG. 3C is a plane view of the radiating fin of the present invention instill another aspect;

FIG. 4A is a top view of the main body of the present invention;

FIG. 4B is a perspective view of the main body of the present invention;

FIG. 4C is a top view showing the radiating fins of the presentinvention;

FIG. 5A is a top view of the main body of the present invention inanother aspect;

FIG. 5B is a perspective view of the main body of the present inventionin the other aspect;

FIG. 5C is a top view showing the radiating fins of the presentinvention in another aspect;

FIG. 5D is a perspective view of one single radiating fin of the presentinvention in the other aspect;

FIG. 6A is a view showing that the main body connection section of themain body of the present invention is formed with raised/recessednon-planar surface;

FIG. 6B is an enlarged view of circled area of FIG. 6A;

FIG. 6C is a view showing that the first connection section of theradiating fin of the present invention is formed with raised/recessednon-planar surface;

FIG. 6D is an enlarged view of circled area of FIG. 6C;

FIG. 7A is a view showing that the first connection section is connectedto the main body connection section in a first state;

FIG. 7B is a view showing that the first connection section is connectedto the main body connection section in a second state;

FIG. 7C is a view showing that the first connection section is connectedto the main body connection section in the first state, in which theradiating fin has a bending angle;

FIG. 7D is a view showing that the first connection section is connectedto the main body connection section in the second state, in which theradiating fin has a bending angle;

FIG. 7E is a view showing that the first connection section is connectedto the main body connection section in the first state, in which theradiating fin has a first bending root section;

FIG. 7F is a view showing that the first connection section is connectedto the main body connection section in the second state, in which theradiating fin has a first bending root section;

FIG. 8A is a view showing that two radiating fins are connected to oneconnection channel;

FIG. 8B is a view showing that the two radiating fins have differentthicknesses;

FIG. 8C is a view showing that the two radiating fins have differentbending angles;

FIG. 8D is a view showing that the two radiating fins have equal bendingangles;

FIG. 8E is a view showing that the two radiating fins have differentbending root sections;

FIG. 9 is a flow chart of the manufacturing method of the presentinvention;

FIG. 10 shows a first step of the manufacturing method of the presentinvention;

FIG. 11A shows a second step of the manufacturing method of the presentinvention;

FIG. 11B shows a third step of the manufacturing method of the presentinvention; and

FIG. 12 is a flow chart of another embodiment of the manufacturingmethod of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Please refer to FIGS. 1 and 2. FIG. 1 is a perspective exploded view ofthe present invention. FIG. 2 is a perspective assembled view of thepresent invention. The heat sink 10 of the present invention includes amain body 12 and multiple first radiating fins 13 connected to an outercircumference of the main body 12. The main body has a first end 121 anda second end 122.

As shown in FIG. 1, the first and second ends 121, 122 of the main body12 define a longitudinal direction a. Referring to FIG. 4B, multiplemain body connection sections 123 are formed on the surface of the mainbody and extend from the first end 121 to the second end 122 in thelongitudinal direction a. (The main body connection sections 123 aredistributed over the outer circumference of the main body equivalentlyor inequivalently). The main body 12 is formed with multiple thrustsections 124 near the first end 121 in communication with the main bodyconnection sections 123 (as shown in FIG. 4B). The thrust sections 124make it easier to fit the first radiating fins 13 into the main bodyconnection sections 123 from the first end 121 of the main body 12. Theform of the thrust sections 124 is varied with the form of the main bodyconnection sections 123. This will be detailedly described hereinafter.

As shown in FIGS. 1 and 2, the multiple first radiating fins 13 areannularly arranged around the surface of the main body 12. Each firstradiating fin 13 has a first connection section 131 corresponding to themain body connection section 123 of the main body 12. The firstconnection section 131 can be thrust into the main body connectionsection 123 from the first end 121 to the second end 122 in thelongitudinal direction a so as to integrally connect the first radiatingfin 13 with the main body 12.

Further referring to FIGS. 3A to 3C, the first connection section 131 isformed with a right angle 132 or a guide section. For example, the guidesection is, but not limited to, a round angle 133 a or a reverse angle133 b. By means of the guide section, the first connection section 131can be easily and smoothly thrust into the thrust section 124 and themain body connection section 123.

Please further refer to FIGS. 4A to 4C. Also referring to FIG. 3A, in apreferred embodiment, the main body connection section 123 is aconnection channel and the thrust section 124 is also a connectionchannel. The thrust section 124 has a width slightly larger than that ofthe main body connection section 123 (as shown in FIGS. 4A and 4B). Thefirst connection section 131 is a first end edge of the first radiatingfin 13 (as shown in FIGS. 3A and 4C). The first connection section 131is connected to the main body connection section 123 (as shown in FIG.4B) by means of press fit.

Please further refer to FIGS. 5A to 5D. In another embodiment, the mainbody connection sections 123 a are ribs and the thrust sections 124 aare also ribs. The thrust section 124 a has a width slightly smallerthan that of the main body connection section 123 a (as shown in FIGS.5A and 5B). The first connection section 131 a is a connection channel(as shown in FIGS. 5C and 5D). The first connection section 131A isconnected to the main body connection section 123A (as shown in FIG. 5A)by means of press fit.

Please further refer to FIGS. 6A and 6B. In another embodiment, the mainbody connection section 123 is formed with a raised/recessed non-planarsurface 1231, while the first connection section 131 has a planarsurface (as shown in FIG. 4C). Alternatively, as shown in FIGS. 6C and6D, in another embodiment, the first connection section 131 is formedwith a raised/recessed non-planar surface 1311 and the main bodyconnection section 123 has a planar surface (as shown in FIG. 4A). Thiscan enhance the connection friction therebetween to avoid detachment ofthe first connection section 131. The configurations of the main bodyconnection section and the first connection section are not limited tothe above embodiments. In still another embodiment, both the main bodyconnection section 123 and the first connection section 131 are formedwith raised/recessed non-planar surfaces 1231, 1311, which are matedwith each other (as shown in FIGS. 6A to 6D).

Many embodiments of the main body connection sections 123 of the mainbody 12 and the first radiating fins 13 will be described hereinafter.

As shown in FIG. 7A, the main body connection sections 123 areconnection channels radially distributed over the circumference of themain body 12. The main body connection sections 123 are normal to thesurface of the main body 12. The first radiating fin 13 is straight fromthe first connection end 131 to an outer free end without bending.

As shown in FIG. 7B, in another embodiment, the main body connectionsections 123 are connection channels radially distributed over thecircumference of the main body 12. The main body connection sections 123are inclined to the surface of the main body 12. The first radiating fin13 is straight from the first connection end 131 to an outer free endwithout bending.

As shown in FIGS. 7C and 7D, in another embodiment, the first radiatingfin 13 a has at least one end first bending angle 1234 a. In the casethat the heat sink is used in cooperation with a cooling fan, the fluidpassing through the cooling fan is easy to go into the flow ways betweenthe first radiating fins 13 a and then quickly flow out to carry awaythe heat.

As shown in FIGS. 7E and 7F, in another embodiment, the first connectionsection 131 c of the first radiating fin 13 c is formed with a firstbending root section 135 c connected in the main body connection section123, 123 c of the main body 12. Similarly, in the case that the heatsink is used in cooperation with a cooling fan, the fluid passingthrough the cooling fan is easy to go into the flow ways between thefirst radiating fins 13 c and then quickly flow out to carry away theheat.

Please now refer to FIG. 8A. Also referring to FIG. 1, in anotherembodiment, the heat sink further includes multiple second radiatingfins 14. Each second radiating fin 14 has a second connection section141 immediately adjacent to the first connection section 131 of thefirst radiating fin 13. Along with the first connection section 131, thesecond connection section 141 is high-speed thrust into the main bodyconnection section 123 from the first end 121 of the main body 12 to thesecond end 122 in the longitudinal direction a. In this embodiment, themain body connection section 123 is a connection channel, while thefirst connection section 131 is a first end edge of the first radiatingfin 13 and the second connection section 141 is a second end edge of thesecond radiating fin 14. That is, at least one first connection section131 and one second connection section 141 are tightly fitted in oneconnection channel (the main body connection section 123) with the firstradiating fin 13 adjacent to the second radiating fin 14.

Moreover, as shown in the drawings, the first radiating fin 13 isstraight from the first connection section 131 to an outer free endwithout bending. Also, the second radiating fin 14 is straight from thesecond connection section 141 to an outer free end without bending. Thefirst radiating fin 13 has a first thickness f1 and the second radiatingfin 14 has a second thickness f2. The first thickness f1 is equal to thesecond thickness f2.

As shown in FIG. 8B, in another embodiment, the first thickness f1 ofthe first radiating fin 13 is unequal to the second thickness f2 of thesecond radiating fin 14.

The first radiating fin 13 is made of a first material, while the secondradiating fin 14 is made of a second material. The first material is ametal material and the second material is also a metal material. Thefirst material is identical or not identical to the second material. Themetal is selected from a group consisting of gold, silver, copper andaluminum.

As shown in FIGS. 8C and 8D, in another embodiment, the first radiatingfin 13 e has a first bending angle 134 e, while the second radiating fin14 e has a second bending angle 144 e. The angle of the first bendingangle 134 e is unequal to the angle of the second bending angle 144 e(as shown in FIG. 8C) or equal to the angle of the second bending angle144 e (as shown in FIG. 8D).

As shown in FIG. 8E, in still another embodiment, the first radiatingfin 13 f is formed with a first bending root section 135 f and thesecond radiating fin 14 f is formed with a second bending root section145 f. The first and second bending root sections 135 f, 145 f areconnected in the main body connection section 123 of the main body 12.In this embodiment, the main body connection section 123 is a connectionchannel, while the first connection section 131 f is a first end edge ofthe first radiating fin 13 f and the second connection section 141 f isa second end edge of the second radiating fin 14 f.

In still another embodiment, the first radiating fin 13 and/or thesecond radiating fin 14 are equivalently or inequivalently tightlyconnected to the main body.

Please further refer to FIGS. 9, 10, 11A and 11B. FIG. 9 is a flow chartof the manufacturing method of the present invention. The manufacturingmethod of the present invention includes steps of:

61. providing a mold 40 as shown in FIG. 10, the mold 40 having an innercircumference 41, an upper surface 42 and multiple splits 43, the innercircumference 41 defining an internal space 44 in which a central body45 is disposed, the multiple splits 43 being radially formed around theinternal space 44 in communication with the internal space 44 anddownward extending from the upper surface 42;

62. providing the main body 12 as shown in FIG. 10, the first end 121 ofthe main body 12 being aimed at the central body 45 disposed in theinternal space 44 of the mold 40, the main body 12 being temporarilypositioned above the mold 40 with the first end 121 of the main body 12aimed at the central body 45;

63. providing the multiple first radiating fins 13 as shown in FIGS. 10and 11A, the first radiating fins 13 being received in the splits 43with the first connection sections 131 protruding from the innercircumference 41 of the mold 40, each the first connection section 131being aligned with one of the main body connection sections 123 and oneof the thrust sections 124; and

64. using a mechanical processing measure (air compression effect) tohigh-speed impact the main body 12 as shown in FIGS. 10, 11A and 11B tothrust the main body 12 toward the central body 45 into the internalspace 44 and move the main body 12 relative to the multiple firstradiating fins 13, at this time, the first connection sections 131 ofthe first radiating fins 13 being thrust from the thrust sections 124 ofthe first end 121 of the main body 12 into the main body connectionsections 123 and moved in the longitudinal direction a to the second end122 to tightly integrally connect with the main body 12.

In step 64, an air compression apparatus 50 serves as a power source forcreating compressed air. In the instant of relieving the compressed air,a power is generated to push and drive the main body 12 to thrust intothe internal space 44 at high speed. In the meantime, the thrustsections 124 and the main body connection sections 123 are thrust intothe first connection sections 131 from upper side of the mold 40 at highspeed. Accordingly, the main body 12 is integrally connected with thefirst radiating fins 13 to form a heat sink 10. The central body 45serves to ensure that the main body 12 can be downward thrust into theinternal space 44 in correct position along the central body 45. The aircompression apparatus 50 is, but not limited to, an air compressor.

Referring to FIG. 2, after step 64 is completed, the heat sink 10 istaken out from the mold 40.

In the above embodiments, the main body 12 is a hollow body.Alternatively, in another embodiment, the main body 12 can be a solidbody. In the case that the main body 12 is a solid body, no central bodyis disposed in the internal space 44 of the mold 40.

FIG. 12 is a flow chart of a second embodiment of the manufacturingmethod of the present invention. The second embodiment is substantiallyidentical to the first embodiment and thus will not be repeatedlydescribed hereinafter. The second embodiment is different from the firstembodiment in that after step 62, the second embodiment of themanufacturing method of the present invention includes steps of:

73. providing the multiple first radiating fins 13 and multiple secondradiating fins 14, the first and second radiating fins 13, 14 beingreceived in the splits 43 with the first connection sections 131 of thefirst radiating fins 13 and the second connection sections 141 of thesecond radiating fins 14 protruding from the inner circumference 41 ofthe mold 40.

74. using an air compression effect to high-speed impact the main bodyto thrust the main body 12 toward the central body 45 into the internalspace 44 and move the main body 12 relative to the first and secondradiating fins 13, 14, at this time, the first connection sections 131of the first radiating fins 13 and the second connection sections 141 ofthe second radiating fins 14 being thrust from the thrust sections 124of the first end 121 of the main body 12 into the main body connectionsections 123 and moved in the longitudinal direction a to the second end122 to tightly integrally connect with the main body 12.

Referring to FIG. 8A, after step 74 is completed, the heat sink 10 istaken out from the mold 40.

The present invention has been described with the above embodimentsthereof and it is understood that many changes and modifications in theabove embodiments can be carried out without departing from the scopeand the spirit of the invention that is intended to be limited only bythe appended claims.

1-18. (canceled)
 19. A manufacturing method of a heat sink, comprisingsteps of: providing a mold, the mold having an inner circumference, anupper surface and multiple splits, the inner circumference defining aninternal space, the multiple splits being radially formed around theinternal space in communication with the internal space and downwardextending from the upper surface; providing a main body having a firstend and a second end, the first and second ends of the main bodydefining a longitudinal direction, multiple main body connectionsections being formed between the first and second ends and distributedover a circumference of the main body, the first end of the main bodybeing aimed at the internal space; providing multiple first radiatingfins, the first radiating fins being received in the splits, at leastone first radiating fin being placed in each split, each first radiatingfin having a first connection section, the first connection sections ofthe first radiating fins protruding from the inner circumference of themold; and using a mechanical processing measure to high-speed impact themain body so as to thrust the main body into the internal space and movethe main body relative to the multiple first radiating fins, whereby thefirst connection sections of the first radiating fins are high-speedthrust into the main body connection sections and moved in thelongitudinal direction to the second end to tightly integrally connectwith the main body.
 20. The manufacturing method of the heat sink asclaimed in claim 19, wherein the main body is temporarily positionedabove the mold and the mechanical processing measure is an aircompression apparatus for creating compressed air to thrust the mainbody into the internal space.
 21. The manufacturing method of the heatsink as claimed in claim 19, wherein a central body is disposed in theinternal space in alignment with the main body.
 22. The manufacturingmethod of the heat sink as claimed in claim 19, wherein multiple secondradiating fins are further provided, the first and second radiating finsbeing together received in the splits, at least one first connectionsection and at least one second connection section being placed in eachsplit, each second radiating fin having a second connection section, thesecond connection sections of the second radiating fins protruding fromthe inner circumference of the mold to be thrust into the main bodyconnection sections and connected with the main body.